• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.117-120
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• 2003

Warm deep drawing which is one of the new forming technologies to improve formability of sheet metal is applied to the cylindrical cup drawing of Mg-alloy sheet metal. In experiments the temperature of die and blank holder is varied from room temperature to $300^{\circ}C$, while the punch is cooled by circulation of coolant to increase the fracture strength of workpiece on the punch corner area. Test material chosen for experiments is AZ31 magnesium sheet metal. Teflon film as a lubricant is used on both sides of a workpiece. The limit drawing ratio as well as thickness distributions of drawn cups are investigated and validity of warm deep drawing process is also discussed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.393-396
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• 2003

A systematic investigation for the process design in deep drawing is necessary to improve the quality of drawn cups. This study concentrates mainly on the influence of process design strategy on the product quality. Several types of process design were chosen from initial blank of 100mm in diameter to make final cup of 50mm in diameter. Forming analysis are carried out to find out optimal design in terms of drawing force. We assume that the case which shows minimum drawing force in the subsequent operations is the best case. Through experiments it is found that the case which shows minimum drawing force also results in minimum drawing force and better product quality than other case. Thus, it is shown that this design strategy is very effective in the improvement of quality in drawn cups.

• Transactions of Materials Processing
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• v.6 no.4
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• pp.300-310
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• 1997

A finite element inverse method is introduced for direct prediction of blank shapes, strain distributions, and reliable intermediate shapes from desired final shapes in axisymmetric multi-step deep drawing processes. This mothod enables the determination of process disign. The approach deals with the Hencky's deformation theory. Hill's second order yield criterion, simplified boundary conditions, and minimization of plastic work with constraints. The algorithm developed is applied to motor case forming, and cylindrical cup drawing with the large limit drawing ratio so that it confirms its validity by demonstrating resonably accurate numerical results of each problem. Numerical examples reveal the reason of difficulties in motor case forming with corresponding limit diagrams.

• Journal of Power System Engineering
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• v.7 no.2
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• pp.61-65
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• 2003

Sheet metal forming process is a non-linearity problem which Is affected by various process variables, such as geometric shape of punch and die, frictional characteristic, etc.. Therefore, the knowledge of the influence of the process variables is needed in the design of sheet metal working processes. In this paper, deep drawing tests for blank holding force, punch speed and lubrication between sheet material and tool were carried out to investigate the influence upon sheet formability. Experimental results were discussed about the defects on the deformation behaviors during the forming process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.1593-1596
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• 2003

Sheet metal forming process is a non-linearity problem which is affected by various process variables, such as geometric shape of punch and die, frictional characteristic, etc.. Therefore, the knowledge of the influence of the process variables is needed in the design of sheet metal working processes. In this paper, deep drawing tests for blank holding force, punch speed and lubrication between sheet material and tool were carried out to investigate the influence upon sheet formability. Experimental results were discussed about the defects on the deformation behaviors during the forming process.

• Transactions of the Korean Society of Mechanical Engineers
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• v.14 no.5
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• pp.1129-1137
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• 1990

Based on the formulation which incorporates large deformation and anisotropy, an elastic-plastic finite element code is developed with membrane element to include the contact treatment. For the analysis of the general sheet metal forming process with contact condition, the treatment of contact is considered by employing the successive skew coordinate system. Three kinds of sheet metal forming processes with contact conditions are analyzed; stretching of a square diaphragm with a hemispherical punch, deep drawing of a circular cup and deep drawing of a square cup. Then the computational results are compared with the experiment. The computed loads and the distribution of the thickness strain are in good agreement with the experiment for all cases. However, the computational results of the thickness strain show the effect of bending can not be ignored in the deep drawing process whereas the effect of bending is negligible in stretching.

• Transactions of Materials Processing
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• v.20 no.1
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• pp.36-41
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• 2011

Meso-scale or micro-scale forming of sheet metal parts has been recently considered as one of the important forming technologies with growing demand on meso/micro products for electric or medical devices. Experimental investigation on the cylindrical meso-cup drawing with hemispherical punch is carried out to examine the limit drawing ratio and thickness distribution of drawn cups. The working parameters chosen in this study are blank diameter, die-corner radius and blankholding force. It is found from the experiments that the limit drawing ratio of 2.4 can be achieved in the case of hemispherical cup drawing and uniform thickness distribution in wider region can be obtained compared with the results of conventional cup drawing.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.10a
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• pp.124-127
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• 2000

The finite element analyses of the wrinkling initiation and growth in the sheet metal forming process provide the detailed information about the wrinkling behavior of sheet metal. The direct analyses of the wrinkling initiation and growth, however, bring about a little difficulty in complex industrial problems because it needs large memory size and long computation time. For the description of wrinkling growth, the mesh elements should be sufficiently small and the size of finite element matrix becomes large. In the static implicit finite element method therefore, the direct analysis of wrinkling growth in a complex sheet metal forming process is rather difficult. From the industrial viewpoint of tooling design, the readily available information of possibility and location of wrinkling is sometimes more preferable to the detailed time-consuming information. In the present study, therefore, the wrinkling factor that shows locations and relative possibility of wrinkling initiation is proposed as a convenient tool of relative wrinkling estimation based on the energy criterion. The location and relative possibility of wrinkling initiation are predicted by calculating the wrinkling factor in various sheet metal forming processes such as cylindrical cup deep drawing, spherical cup deep drawing, and elliptical cup deep drawing. The wrinkling factor is also implemented in the analysis of the door inner stamping process to predict wrinkling.

• Transactions of Materials Processing
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• v.16 no.8
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• pp.590-595
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• 2007

This paper introduces a new approach to take account of bending history in finite element inverse analysis during sheet metal forming process. A modified membrane element was adopted for finite element inverse analysis so that bending-unbending energy was additionally imposed in the total plastic energy, predicting bending-unbending regions using the geometry of the final shape and tools. An algorithm was applied to a cylindrical cup deep drawing process. The blank shape and the distribution of the thickness strain were compared with those obtained from the incremental finite element analysis in order to evaluate the effect of the bending history. The algorithm reduced the difference between the results of the inverse analysis from those of the incremental analysis due to bending history. The analysis was also carried out with the variation of the thickness of the initial blank to investigate the effect of bending deformation. The results showed that the difference was remarkably reduced as the thickness of the initial blank increased. This indicates that the finite element inverse analysis cooperated with the suggested scheme is useful to obtain more accurate results, especially when bending effects are significant.

• Journal of the Korean Society for Precision Engineering
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• v.7 no.3
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• pp.56-65
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• 1990

This paper describes a computer aided tool design system of deep drawing of cylindrical cups with or without flange by press. An approach to system is based on knowledge based system. The computer program has written in basic language with personal computer Knowledges for tool design are formulated from the plasticity theory, handbooks, experimental results and empirical knowhow of the field experts. The capabilities of developed system include 1) the selection of tool structure (with or without blank holder, single or double action, lift up or draw off type), 2) the design of tool elements(punch/holder, die/holder etc.) for the previous selected tool structure by the process planning output and the production quantity. The final output is generated in graphics form for design sheet.